GAS METAL ARC

WELDING (GMAW)
 DEFINITION
Gas metal arc welding(GMAW), sometimes referred to by its
subtypesmetalinertgas(MIG)weldingormetalactivegas(MAG)welding,
is aweldingprocess in which an electricarc forms between a consumable
wire electrode and the workpiecemetal(s), which heats the
workpiecemetal(s), causing them to melt and join.
 WHAT MUST BE CONSIDERED WHEN
SELECTING THE TYPE OF TRANSFER
Type, intensity and polarity of welding current
Electrode size
Electrode composition
Electrode extension
Shielding gas mix composition
 DIFFERENT TYPES OF TRANSFER METHODS

Short Circuit Transfer

Globular Transfer
Spray Transfer
Pulse Spray Transfer
 SHORT CIRCUIT TRANSFER

In short circuit transfer, the electrode touches the work and short circuits,
causing the metal to transfer as a result of the short. This happens at a
rate of 20 to more than 200 times per second
Operates at low voltages and welding current
Small fast freezing weld puddle can be obtained from this
Can be used to join thin materials in any position, as well as thick
materials n vertical and overhead positions
 SHORT CIRCUIT
A electrode is short circuited to base metals.
No arc and current is flowing through electrode
wire and base metal
B resistance increases in electrode wire
causing it to heat, melt and neck down
C electrode wire separated from weld puddle,
creating an arc. Small position of electrode
wire is deposited which forms a weld puddle
D arc length and load voltage are at
maximum. Heat of arc is flatterning the puddle
and increasing the diameter tip of electrode
E wire feed speed overcomes heat of arc and
wire approaches base metal again
F arc is off and the short circuit cycle starts
again.
 GLOBULAR TRANSFER
Globular transfer means the weld metal transfer across the arc in large
droplets, usually larger than the diameter of the electrode being used.
This mode of transfer generally is used on carbon steel only and uses
100% CO2 shielding gas.
Welding current and wire speed are above maximum for short arc
Welding is most effectively done in the flat position when using globular
transfer
 GLOBULAR TRANSFER
Globular transfer is often a high voltage,
high amperage, high wire feed speed
transfer.
 SPRAY ARC TRANSFER
This happens when the current and the voltage settings are increased
higher than that used for globular transfer
Used on thick sections of base material, best suited for flat position due
to large weld puddle
Spatter in minimal to none
Uses 5% to 10% CO2 mix with argon or oxygen
 SPRAY TRANSFER
Spray arc transfer sprays a
stream of tiny molten
droplets across the arc,
from the electrode wire to
the base metal
Spray arc transfer uses
relatively high voltage,
wire feed speed and
amperage values,
compared to short circuit
transfer.
 PULSE SPRAY TRANSFER

The welding current alternates between a peak current and a lower

background current
This faster-freezing weld puddle is what allows the pulsed-spray transfer
to be used for thinner metals
Better control on out of position work
Allows for larger wire sizes to be used on varied metal thickness
 PULSE SPRAY TRANSFER
In pulse spray transfer the
welding power sources
pulse control pulses the
welding output with high
peak currents which are set
at levels which will cause
transfer to go into a spray.
The background current is
set at a level that will
maintain the arc, but Is too
low for any metal transfer to
occur
 TOOLS USED IN GMAW
A welding gun
A wire feed motor and welding
control
A welding power supply
A welding electrode wire
A shielding gas supply
 WELDING GUN
The welding gun guides the
wire and shielding gas to the
welding zone
Major components of the torch
are the contact tip, shielding
gas nozzle, gas diffuser and the
wire conduit.
 WIRE FEED MOTOR AND
WELDING CONTROL
These two are combined to
make one unit
The main function of this part is
to pull the wire from the spool
and to feed it to the arc
This also controls wire feed
speed and regulates the starting
and stopping of wire feed
The wire feed is used to control
the amperage
 TYPES OF WIRE FEED MOTOR
Two roll drive
system
Four roll drive
system

Two roll drive system

Four roll drive system
WIRE FEEDER
 POWER SOURCE
Provides a relatively
consistent voltage to the arc
Arc voltage is the voltage
between the end of the wire
and the work piece
Negative lead is connected to
the workpiece
Positive lead is connected to
the torch
 SHIELDING GAS
The gas can be inert,
reactive, or mixtures of
both
Argon, helium and carbon
dioxide are the main three
gases used in GMAW
The shielding gas is to
protect the weld area from
the contaminants in the
atmosphere
Gas flow rate is between
25-35 CFH
 SAFETY PRECAUTIONS TO BE
OBSERVED
Ensure there is ventilation to remove dangerous fumes
Do not weld near combustible materials
Do not weld near water
Protect persons who are near from arc rays
Keep welding cables and jobs free grease
 GEARS TO BE WORN
PROCEDURE
Cotton clothing should be worn
Wear leather gloves
Wear helmet to protect eyes from the sun
Safety glasses when chipping slag